500 Amp Carbon Pile Load Tester

Item 91129

500 AM
CARBON P WARNING

LOAD TE PILE
Testing
Capability
STER
Load Test 12 VDC
Capacity Batteries,
Display 160 Ah; Alternators,
Meters 1000 CCA and Starter
Analog, max. testing s
Test Cycle 0-16 ; 0-500A
15 second VDC (max.); Analog load
s
Battery
Cables 3 tests in per test with a , 0-500A
5 minute 1 minute
3’ x 4 AWG s maxim cool down; To preven
with copper um
-plated clamps
t serious
1. Wear injury and
ANSI-a burns:
heavy-duty pproved safety

OFF 2. Do not
touch
work gloves

Vents get tester’s vents during

goggles
during setup and
and use.

LOAD 3. Inspec
VERY HOT
t before every
do not use use;
if parts loose
or
during use. after use.

4. Use as or damag
intended ed.
5. Read only.
manual before
set up and/or
use.
04b-11e

ITEM 91129

Read this material before using this

Made in
China.

product. Failure to do so can result in

serious injury. SAVE THIS MANUAL.

When unpacking, make sure that the product is intact and undamaged.
If any parts are missing or broken, please call 1-800-444-3353 as soon as possible.

Visit our website at: http://www.harborfreight.com

Copyright© 2004 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape
or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included.
Manual Revised 11e
Save This Manual
Keep this manual for the safety warnings and precautions, assembly, operating, inspection,
maintenance and cleaning procedures. Write the product’s serial number in the back of the
manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.

Safety Alert Symbol and Signal Words

In this manual, on the labeling, and all other
information provided with this product:
CAUTION, used with the safety alert symbol,
This is the safety alert symbol. It is indicates a hazardous situation which, if not
used to alert you to potential personal avoided, could result in minor or moderate injury.
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
NOTICE is used to address practices
not related to personal injury.

DANGER indicates a hazardous situation which, if

not avoided, will result in death or serious injury. CAUTION, without the safety alert symbol, is used
to address practices not related to personal injury.

WARNING indicates a hazardous situation which, if

not avoided, could result in death or serious injury.

IMPORTANT SAFETY INSTRUCTIONS

INSTRUCTIONS PERTAINING TO A 6. Maintain this product. Check for breakage
of parts and any other condition that may
RISK OF FIRE, ELECTRIC SHOCK, affect this product’s operation. If damaged,
OR INJURY TO PERSONS have the unit repaired before use.

WARNING – When using tools, basic precautions
should always be followed, including the following:
1. Wear ANSI-approved safety goggles during
set up and use of the Load Tester.
7. Use this product in accordance with these
instructions, taking into account the working
conditions and the work to be performed. Use
of this product for operations different from those
intended could result in a hazardous situation.

2. Test in a well ventilated area. Explosive
gases may be produced during testing.
Do not smoke, cause sparks, or strike
matches near the battery when testing.
3. Always refer to the user manual of the battery/
alternator being tested for testing instructions
and precautions prior to using the Load Tester.
4. Do not reverse the polarity of the Battery & Alternator
Tester’s Ring Terminals or vehicle battery.
5. Do not expose this product to rain or wet conditions.
8. This product is not a toy. Keep it
out of reach of children.
9. Maintain labels and nameplates on the unit.
These carry important safety information.
If unreadable or missing, contact Harbor
Freight Tools for a replacement.
10. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.
Caution is necessary when near coil, spark plug
cables, or distributor of running engine. Engine
should be off during distributor adjustment.

Page 2 For technical questions, please call 1-800-444-3353. SKU 91129

Specific Safety Instructions
1. When connecting the Battery Cables to the terminal of the battery. Reversing Load Tester Cable
battery, avoid creating sparks; especially when Clamps on the battery will damage the tester.
the battery is being charged. Explosive gases
are created during charging. Sparking could 5. Do not drop the Load Tester.
also damage the vehicle electrical system.
6. Do not smoke or have open flames near the battery.
2. Do not touch the cooling vents on the Load
7. Do not connect the Load Tester to the
Tester during or immediately after testing
battery while the engine is running.
the battery. They become very hot.
Turn the engine off before connecting.
3. When placing the Load Tester in the vehicle’s
8. The warnings and precautions discussed in this
engine compartment, take special care that
manual cannot cover all possible conditions and
the metal housing of the Tester does not
situations that may occur. It must be understood
come in contact with either terminal of the
by the operator that common sense and caution
battery or other electrical connections.
are factors which cannot be built into this
4. Be certain of the test battery polarity before product, but must be supplied by the operator.
connecting the test Cable Clamps. The red Cable
Clamp goes to the positive terminal of the battery.
The black Cable Clamp goes to the negative
SAVE THESE
INSTRUCTIONS.

Specifications

Testing
12 VDC batteries, alternators, starters
Capability
160 amp hour
Load Test
Up to 1000 cold cranking amps
Capacity
0 ~ 500A load
Analog, 0 ~ 16 VDC (max.)
Display Meters Analog, 0 ~ 500A; 0 ~ 160Ah;
0 ~ 1000 CCA
15 seconds per test with 1 minute
Test Cycle cool down
3 tests in 5 minutes maximum
Battery Cable 3 FT. long; copper plated clamps;
/ Clamps #4 AWG

SKU 91129 For technical questions, please call 1-800-444-3353. Page 3

 Operating Instructions

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.

Inspect tool before use, looking for damaged, loose, and missing parts.
If any problems are found, do not use tool until repaired.

Testing the Battery

1. Wipe the battery terminals with a cloth (Ah) capacity of the battery. The CCA and
to remove any dirt and grease. AH rating are printed on the battery label.

2. Make sure the Load Knob (C) is in the off position. 5. Maintain load for 15 seconds. After 15 seconds
Connect the red (positive) Cable Clamp (A) to has passed, the unit will sound with a beep.
the positive terminal (+) on the 12 V battery.
See photo on page 4. 6. View the DC Volts Meter and read the
battery condition. Refer to the “Battery
3. Connect the black (negative) Cable Clamp (B) Condition Analysis” section on page 5.
to the negative terminal (­–) on the battery.
7. Turn the Load Knob (C) counterclockwise to Off,
4. Turn the Load Knob (C) clockwise until the and remove the Cable Clamps from the battery.
DC ammeter reads 1/2 the Cold Crank Amp
(CCA) rating or three times the amp-hour NOTE: Freezing temperatures affect the battery test
reading. Decrease the battery rating 50 cold cranking
amps for each 50°F (10°C) below freezing 32°F (0°C).

DC Amp Meter DC Volt Meter

Battery Test:
Green - OK
Amp Scale Red - Replace

Amp Hour
Scale
State of Charge:
CCA Scale Green - OK
Red - Recharge
Load
Knob (C)
Alternator &
500 AM
CARBON P WARNING Regulator Test:
LOAD T PILE Green - OK
Testing
Capabili
ESTER
Red - Low
Load Test ty 12 VDC
Capacity Batterie
Display 160 Ah; s, Alternat
Meters 1000 CCA ors, and
Analog, max. test Starters
Test Cyc 0-16 ing; 0-50
le 15 seconds VDC (max.); Ana 0A load
log, 0-50
Battery
Cables 3 tests in per test with a 0A
5 minutes 1 minute
3’ x 4 AWG maximu cool dow
with cop m n; To prevent
per-plated serious
clamps 1. Wear injury and
ANSI-ap burns:
heavy-duty proved safety

OFF 2. Do not
touch
work glov
es during
Vents get tester’s vents duri
goggles
and
setup and
use.

LOAD 3. Inspect
VERY HOT
befo
do not use re every use;
if parts loos
ng or
during use after use.
.

4. Use as e or dam
intended aged.
5. Read only.
manual befo
re set up
and/or use
.
04b-11e

ITEM 911
29
Made in
China.

Negative Cable (-) Positive Cable (-)

Black Cable Red Cable

(Clamp B) (Clamp A)

Page 4 For technical questions, please call 1-800-444-3353. SKU 91129

Testing the Charging System

AVOID CARBON MONOXIDE POISONING.

This gas comes from the vehicle’s exhaust and is colorless and odorless.
It can cause SERIOUS INJURY or DEATH if inhaled.

1. Turn the Load Knob (C) counterclockwise
to the Off position.
2. Connect the Cable Clamps to the
battery as previously described.
3. Outside, or in a well ventilated area, start the
vehicle engine and run at fast idle speed.
4. View the DC Volt Meter and read the
Alt. - Reg. condition. Refer to the
“Battery Condition Analysis” section.
5. Turn the vehicle’s engine off, then remove
the Load Tester Cable Clamps.

Battery Condition Analysis

Load Test / 15 Seconds
Battery Condition
(Display Reading)
Battery capacity is good. May or may not be fully charged. Check the
OK charge state by testing the Specific Gravity (SG) with a Hydrometer.
(Green Area) If SG is less than full charge, check for possible
charging system trouble. Recharge to full level.
If the DC Volt Meter needle is falling, the battery is defective or has a
bad cell.
Bad For a quick check, turn the Load Knob down, counterclockwise,
(Red Area) and note DC Volt Meter reaction. If voltage recovers to its
full potential after only a few seconds, the battery is probably
defective. If the voltage recovers slowly, the battery may only be
run down. Check specific gravity level, recharge and re-test.
Charging System If the DC Volt Meter needle reads OK, charging system
(Alt. & Reg Test) is functional. If it falls on the low red or high red areas,
charging system may be malfunctioning.

Starter Motor Test

NOTE: If starting your vehicle is difficult, you may have unnecessary starter motor draw, which
dramatically shortens battery life. This test identifies starter motor performance.

1. Make sure your engine is running at normal 5. While watching the DC Volt Meter (see page 4),
operating temperature, and that the battery crank the engine briefly to determine
is fully charged and in good condition. the voltage reading during cranking.

2. Turn the Load Knob (C) counterclockwise
to the Off position.
3. Connect the Red Clamp (+) to the
positive (+) terminal post on the battery.
Connect the Black Clamp (-) to the
negative (-) terminal post on the battery.
4. Disable the engine to make sure the car will not start.
Refer to your vehicle’s service / technical manual.
A display reading of 9 volts or less indicates
excessive current draw. This may be caused by
a bad connection of a failing starter motor, or, the
battery is too small for the vehicle’s requirements.
Consult a qualified mechanic.
6. When starter motor test is complete,
remove Black Clamp (-) from battery first;
then remove Red (+) clamp.

SKU 91129 For technical questions, please call 1-800-444-3353. Page 5

 User‑Maintenance Instructions

Procedures not specifically explained 1. Periodically check all nuts, bolts,

in this manual must be performed and screws for tightness.
only by a qualified technician.
2. Store in a clean, dry location.

3. Clean the outside of the unit with a damp cloth.

TO PREVENT SERIOUS INJURY FROM Never use solvents to clean any parts of this tool.
ACCIDENTAL OPERATION: Allow tool to dry completely before use.
Do not use damaged equipment.
4. Use compressed air to blow out
If abnormal noise or vibration, occurs, have
debris from the load vents.
the problem corrected before further use.
5. After each use, clean the Cable Clamps of
Note: These procedures are in addition to the
any possible battery electrolyte. Apply a thin
regular checks and maintenance explained as part
coat of silicon grease to prevent corrosion.
of the regular operation of the air-operated tool.

Record Product’s Serial Number Here:

Note: If product has no serial number, record month and year of purchase instead.

Replacement parts are not available for this item.

Page 6 For technical questions, please call 1-800-444-3353. SKU 91129

 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure
that its products meet high quality and durability
standards, and warrants to the original purchaser
that this product is free from defects in materials and
workmanship for the period of 90 days from the date
of purchase. This warranty does not apply to damage
due directly or indirectly, to misuse, abuse, negligence
or accidents, repairs or alterations outside our facilities,
criminal activity, improper installation, normal wear and
tear, or to lack of maintenance. We shall in no event
be liable for death, injuries to persons or property, or
for incidental, contingent, special or consequential
damages arising from the use of our product. Some
states do not allow the exclusion or limitation of incidental
or consequential damages, so the above limitation of
exclusion may not apply to you. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES,
SKU 91129 For technical questions, please call 1-800-444-3353.
EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part
must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation
of the complaint must accompany the merchandise. If
our inspection verifies the defect, we will either repair
or replace the product at our election or we may elect
to refund the purchase price if we cannot readily and
quickly provide you with a replacement. We will return
repaired products at our expense, but if we determine
there is no defect, or that the defect resulted from
causes not within the scope of our warranty, then
you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may
also have other rights which vary from state to state.
Page 7
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353